1. Product Overview

The Process Control Module is a key controller component within the ABB Symphony® Plus distributed control system. It undertakes logic execution, closed-loop regulation, data acquisition, and device interlocking functions. As the core hub between field devices and upper-layer systems, it ensures efficient, stable, and coordinated operation of industrial processes.

The module uses the original ABB standard ordering code 3BHE028959R0101, guaranteeing seamless compatibility with the Symphony® Plus architecture and existing ABB I/O subsystems.

2. Key Technical Parameters
2.1 Electrical & Communication Parameters

Power Input:

Redundant 24 VDC (24 V ±10%), compliant with industrial power standards.

Stable failover behavior ensures uninterrupted operation under power switching.

Power Consumption:

Typical operation ≤ 25 W

Standby ≤ 5 W (optimized for long-term continuous service)

Supported Communication Protocols:

ABB proprietary H1 bus

PROFIBUS DP/PA

Modbus RTU / Modbus TCP

EtherNet/IP

Native support allows direct integration with field instruments, actuators, valves, PLCs, and third-party devices.

Communication Interfaces:

2 × Ethernet (10/100 Mbps), supporting redundant ring topology

4 × RS-485 serial ports

1 × H1 bus interface

Control Cycle Time:

Minimum 10 ms, supporting high-speed real-time process control (e.g., pressure/flow loops)

2.2 Control Capability & I/O Adaptation

Supports up to 64 control loops (PID, feedforward, cascade), applicable to complex multivariable processes

Integrated 1024 logic points (DI/DO/AI/AO), expandable up to 4096 points

Fully compatible with ABB Symphony® Plus I/O modules (AI810, AO810, DI810, etc.)

Supports hot-swap expansion, enabling maintenance without system shutdown

2.3 Environmental & Physical Specifications

Operating Temperature: –10 °C ~ +60 °C

Storage Temperature: –40 °C ~ +85 °C

Humidity: 5%–95% RH (non-condensing)

IP Rating: IP20 (for installation inside control cabinets)

Dimensions: 220 × 180 × 80 mm (L × W × H), DIN-rail mount

Weight: ~1.2 kg, modular design for easy installation and replacement

2.4 Reliability & Safety Design

Dual-controller hot redundancy

1:1 architecture

Failover time ≤ 50 ms, switching without process interruption

Protection & Safety Features:

Hardware watchdog

Overvoltage/overcurrent protection

EMC-enhanced design compliant with IEC 61000 (resistant to strong industrial electromagnetic interference)

MTBF ≥ 100,000 h, meeting high-availability requirements in mission-critical industrial applications

ABB PPC902CE101 3BHE028959R0101｜Process Control Unit｜